Method for assembling flush glass assembly

ABSTRACT

A method for assembling an automobile door is provided that comprise providing a lower frame comprising a movable glass piece disposed within an inner panel and an outer panel, a daylight opening module comprising a glass guide, a retaining structure having a channel to slideably retain the glass guide and first and second openings. The method also includes sliding the module downward until a portion of the module contacts the inner panel. The method further includes securing the module to the inner panel.

FIELD OF THE INVENTION

The present invention generally relates to a method for assembling anautomobile door having a flush glass assembly.

BACKGROUND OF THE PRESENT INVENTION

Generally, automotive glass window systems include one or more windowsthat are moveable in a substantially vertical direction. In order toimprove both the aerodynamic and aesthetic characteristics of a vehicle,attempts have been made to eliminate the inboard offset of such glasswindows. Complete elimination of the offset is known as pursuing asubstantially “flush” relationship between the glass windows with theadjacent body and trim surfaces.

Previous attempts to obtain such a flush relationship have been stymiedby inadequate guiding and sealing systems that allow the glass window toremain stable during the substantially vertical motion. Inadequateguiding and sealing systems cause the glass window to be prone tochucking while driving on rough road and binding during typical glassfunction cycling. Additional problems include glass “blow-out” due towind flow vortex around the glass that causes a pressure differentialand sucking of the glass outboard and away from the guiding and sealingsystem.

Accordingly, a method of assembling a flush glass assembly is desiredhaving the aforementioned advantages and solving and/or makingimprovements on the aforementioned disadvantages.

SUMMARY OF THE PRESENT INVENTION

According to one aspect of the present invention, a method forassembling an automobile door is provided that comprise providing alower frame comprising a movable glass piece disposed within an innerpanel and an outer panel, a daylight opening module comprising a glassguide, a retaining structure having a channel to slideably retain theglass guide and first and second openings. The method also includessliding the module downward until a portion of the module contacts theinner panel. The method further includes securing the module to theinner panel.

According to another aspect of the present invention, a method forassembling an automobile door is provided comprising providing a lowerdoor frame comprising an inner panel and an outer panel, wherein amovable glass piece is disposed substantially within the inner panel andthe outer panel. The method also includes providing an upper door framecomprising a daylight opening module, wherein the daylight openingmodule comprises a glass guide, a retaining structure having a channelto slideably retain the glass guide within the upper door frame and thelower door frame, an opening, and an attachment located at a positionforward of the opening, wherein the attachment includes a mirror thatextends substantially orthogonal to the movable glass piece. The methodfurther includes sliding the upper door frame over a top edge of theglass piece and downward until at least a portion of the upper doorframe is in contact with the inner panel of the lower door frame andsecuring the upper door frame to the inner panel.

According to a further aspect of the present invention, a method forassembling an automobile door is provided comprising providing a lowerdoor frame comprising an inner panel and an outer panel, wherein a glasspiece is disposed substantially within the inner panel and the outerpanel. The method also includes providing an upper door frame comprisinga daylight opening module, wherein the daylight opening module comprisesa glass guide and an appliqué having a channel, wherein the channelincludes a seal having a low friction coating or other known materialthat is configured to slideably retain the glass guide. The methodfurther includes sliding the upper door frame over a top edge of theglass piece and downward until at least a portion of the upper doorframe is in contact with the inner panel of the lower door frame andsecuring the upper door frame to the inner panel.

These and other aspects, objects, and features of the present inventionwill be understood and appreciated by those skilled in the art uponstudying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a front perspective view of a first embodiment of anautomobile having a flush glass assembly;

FIG. 2 is an elevated side view of the automobile with a front side doorin an open position;

FIG. 2A is an enlarged view of section IIA in FIG. 2 showing the top andrear side of a glass window;

FIG. 3 is a rear perspective view of the automobile;

FIG. 4 is a side view of a daylight opening module that is employed in avehicle side door;

FIG. 4A is a side view of the daylight opening module without a topcomponent;

FIG. 4B is a side view of the daylight opening module having retainingstructures that extend below a belt line of the automobile door;

FIG. 5 is a top cross-sectional view taken through line V-V of FIG. 2Aillustrating a glass window retaining structure;

FIG. 6 is a top cross-sectional view of the glass window retainingstructure, according to another embodiment;

FIG. 7 is a cross-sectional view taken through an oval-shaped glassguide, according to another embodiment;

FIG. 8 is a cross-sectional view taken through a rectangular-shapedglass guide, according to a further embodiment;

FIG. 8A is a cross-sectional view taken through a tapered glass guide,according to a further embodiment;

FIG. 9 is a side view of a rear daylight opening module that may be usedin a vehicle rear door;

FIG. 9A is a side view of the rear daylight opening module without a topcomponent;

FIG. 10 is a top cross-sectional view taken through line X-X of FIG. 2,illustrating a rear glass window retaining structure;

FIG. 11 is a top cross-sectional view taken through line XI-XI of FIG.3, illustrating the front and rear glass window retaining structures;

FIG. 12 is a front perspective view of a second embodiment of anautomobile having a flush glass assembly;

FIG. 13 is a side elevational view of the second embodiment of theautomobile shown in FIG. 12 with a door in an open position;

FIG. 13A is an enlarged view of section XIIIA of FIG. 13 illustrating atop and rear side of a glass window;

FIG. 14 is a rear perspective view of the automobile shown in FIG. 13;

FIG. 15 is a top view of a glass window retaining structure for theflush glass assembly of the second embodiment of the automobile;

FIG. 16 is a sealing arrangement for sealing two flush glass windows,according to a first embodiment;

FIG. 17 is a sealing arrangement for sealing two flush glass windows,according to a second embodiment;

FIG. 18 is a sealing arrangement for sealing two flush glass windows,according to a third embodiment;

FIG. 18A is a sealing arrangement, according to a fourth embodiment;

FIG. 19 is a side elevational view of a front door of the automobilehaving a lower door frame;

FIG. 20 is a top plan view of the lower door frame;

FIG. 21 is a side elevational view of the front and rear side doors;

FIG. 22 is a top cross-sectional view taken through lines XXII-XXII ofFIG. 21 illustrating the glass window retaining structure disposedwithin the lower door frame, according to one embodiment;

FIG. 22A is a top cross-sectional view of the glass window retainingstructure disposed within the lower door frame, according to anotherembodiment;

FIG. 23 is a top cross-sectional view of the glass window retainingstructure disposed within the lower door frame, according to anotherembodiment;

FIG. 24 is a front elevational view of a side mirror assembled to thedaylight opening module; and

FIG. 25 is a side elevational view of the lower door frame and thedaylight opening module.

DETAILED DESCRIPTION OF EMBODIMENTS

As required, detailed embodiment(s) of the present invention aredisclosed herein;

however, it is to be understood that the disclosed embodiments aremerely exemplary of the invention that may be embodied in various andalternative forms. The figures are not necessarily to a detailed design;some schematics may be exaggerated or minimized to show functionoverview. Therefore, specific structural and functional detailsdisclosed herein are not to be interpreted as limiting, but merely as arepresentative basis for teaching one skilled in the art to variouslyemploy the present invention.

For purposes of description herein, the terms “upper,” “lower,” right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the present invention as oriented in FIG. 1.However, it is to be understood that the invention may assume variousalternative orientations, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary embodiments of theinventive concepts defined in the appended claims. Hence, specificdimensions and other physical characteristics relating to theembodiments disclosed herein are not to be considered as limiting,unless the claims expressly state otherwise.

Referring now to FIGS. 1-3, reference numeral 1 generally designates anautomobile (automotive vehicle) flush glass assembly 11 having a glassguiding and stabilization system 10. In the illustrated example, theassembly 11 comprises a first glass piece 12, a second glass piece 14,and a quarter glass piece 58, where each glass piece 12, 14, 58 includesan inboard surface 48, an outboard surface 50, a front edge 56, and arear edge 54. Each glass piece 12, 14, 58 may be moveable or fixed. Oneor all of the glass pieces 12, 14, 58 may be door window panes (panels)that, when moveable, may be actuated or manually actuated. The movementof the glass pieces 12, 14, 58 is in a substantially vertical directionand closes out a daylight opening of the vehicle. However, with the useof the glass guiding and stabilization system 10, the first glass piece12, the second glass piece 14, and/or a quarter glass piece 58 may bearticulated or rotated into a drop position. The first and second glasspieces 12, 14 are each operably connected to a first and second door 22,24, respectively, where each glass piece 12, 14 rotates in conjunctionwith the first and second doors 22, 24, respectively, about door hinges.The quarter glass piece 58 is operably connected to the second door 24.The operable connection of the glass pieces 12, 14, 58 to the first andsecond door 22, 24 will be described in detail below. Each glass piece12, 14, 58 may be constructed of any glass type suited for automobileapplication. Examples include tempered, laminated, acoustic laminated,ion exchange thin glass, and may include privacy tinting. The glassguiding and stabilization system 10 provides for a flush glass assembly11 in which the glass pieces 12, 14, 58 are in a single plane with outersurfaces of various adjacent vehicle doors and body components.

Located adjacent the front edge 56 (FIG. 4) of the first glass piece 12is a first object 20 that includes an outboard surface 21. The firstobject 20 may comprise a number of automotive components including, butnot limited to, a mirror sail cover, a trim appliqué, belts, interior orexterior trim, badging, etc. The first object 20 may be an individualcomponent or may be part of an integrated, single-unit daylight openingmodule 16, which will be described in detail below. The flush glassassembly 11 may include more than one daylight opening module 16,typically dependent on the number of doors presents, or in other words,the number of daylight openings being integrated into the flushappearance, but this will ultimately depend upon the suitable number forthe particular application. Located adjacent the rear edge 54 of thefirst glass piece 12 is a second object (not labeled). The second objectmay comprise a number of automotive components, including the secondglass piece 14. Additionally, the second object that is locatedimmediately adjacent the rear edge 54 of the first glass piece 12 maycomprise a buffer between the first glass piece 12 and the second glasspiece 14. The buffer may be mounted to one or both of the doors 22, 24,the automobile body side, or the daylight opening module 16. Such abuffer may take the form of a number of components including, but notlimited to, an appliqué 32 or simply a sealing component residingbetween the first glass piece 12 and the second glass piece 14.Irrespective of what the second object comprises, the second objectincludes an outboard surface, as is the case with the first glass piece12, the second glass piece 14, and the first object 20. When the firstand second doors 22, 24 are in a closed position and the first andsecond glass pieces 12, 14 are in a raised position (if moveable), theoutboard surfaces 50, 21 of the glass pieces 12, 14, the first object20, and the second object are all in a single plane, giving all of thesecomponents 12, 14, 20, 32, a flush appearance. One or more of theoutboard surfaces 50, 21 may be tuned to have an over flush appearanceto adjust for wind noise performance. This may also be true for thequarter glass piece 58. Additionally, the automobile header may be flushwith the components.

Similar to the first glass piece 12, the second glass piece 14 hasobjects located immediately adjacent the front edge 56 and the rear edge54. Immediately adjacent the front edge 56 of the second glass piece 14is either the first glass piece 12 or the buffer between the first andsecond glass pieces 12, 14, as described above. As noted above, thebuffer may take the form of several alternative components and may bemounted to one or both of the doors 22, 24, the body side of theautomobile body side, or the daylight opening module 16. To reiterate,the buffer may be an appliqué 32 or a seal of various embodiments. Suchvarious sealing embodiments are illustrated in FIGS. 16-18A. The sealsmay be made of various materials, including thermoplastic vulcanizates(TPVs), thermoplastic polyurethanes (TPUs), thermoplastic polyolefins(TPOs), ethylene propylene diene monomers (EPDMs), etc. Locatedimmediately adjacent the rear edge 54 of the second glass piece 14 isone of various components, including but not limited to, the fixed glasspiece 58 or a buffer between the second glass piece 14 and the fixedglass piece 58. As is the case between the first and second glass pieces12, 14, the buffer may be a channel, an appliqué and/or a sealingcomponent. Continuing the flush appearance of the vehicle, an outboardsurface 60 of the fixed glass piece 58 and/or an outboard surface of thebuffer between the second glass piece 14 and the fixed glass piece 58,as well as the outboard surface 50 of the second glass piece 14 are alloriented in a single plane when the second door 24 is in a closedposition.

Referring to FIGS. 5 and 6, the illustrated glass guiding andstabilization system 10 comprises an arrangement having the appliqué 32disposed between the first glass piece 12 and the second glass piece 14.Although referred to as the appliqué 32, this component is moregenerally a retaining structure 32 that may be made of a number ofmaterials, including but not limited to metal, plastic or an acrylic.The retaining structure 32 is part of a larger component that isgenerally described as the daylight opening module 16 for retainingcomponents, which are described in detail below, that provide guidanceand stability for movement of the glass pieces 12, 14, 58. The daylightopening module 16 may take on various embodiments (FIGS. 4, 4A, 4B, 9and 9A) depending on the application of use, thereby providing designand manufacturing flexibility. Embodiments shown without a top component(FIGS. 4A and 9A) may be particularly useful for convertibles. Thedaylight opening module 16 may comprise a single molded or extrudedpiece or a plurality of components and is operably connected to thefirst or second door 22, 24. For a daylight opening module 16 having aplurality of components, the joining of the components may beaccomplished by welding, including sonic welding, mechanicallyfastening, chemically bonding, an adhesive, and tape, among otherassembly methods. The assembly method of the daylight opening module 16to the first or second door 22, 24 will be described in detail below.

The illustrated retaining structure 32 is oriented in a substantiallyvertical direction and corresponds substantially with the rear edge 54of the first glass piece 12. The retaining structure 32 includes achannel 34 that extends in a substantially vertical direction within theretaining structure 32. The channel 34 may be of any number of geometricconfigurations and within the channel 34 is disposed a seal 36. Thedisposal of the seal 36 within the channel 34 may be accomplished by anadhesive or mechanically fastening the seal 36 therein. The seal 36 maybe extruded or molded (including multi-shot molding process) and may bemade of various materials including, but not limited to thermoplasticvulcanizates (TPVs), thermoplastic polyurethanes (TPUs), thermoplasticpolyolefins (TPOs), ethylene propylene diene monomers (EPDMs), etc. Theseal 36 comprises an outer surface 70 that is at least partially incontact with the retaining structure channel 34 and also an innersurface 72. The cavity formed by the inner surface 72 may take on anynumber of geometries and most, if not all, of the inner surface 72 iscoated with a low friction substance 38, according to one embodiment.The low friction substance 38 may be approximately 50 micrometers (μm)of Tokiwa or a similar coating having a low friction coefficient, but itis conceivable that the substance 38 thickness could range fromapproximately 4 micrometers (μm) to approximately 6 millimeters (mm).

A glass guide 40 is comprised of a body portion 44 and an engagementsection 42. The engagement section 42 is disposed within the seal 36,and more specifically within the coating 38 on the inner surface 72 ofthe seal 36. The engagement section 42 is formed of a geometrycorresponding to the geometry of the cavity formed by the inner surface72 of the seal 36. As noted above, these corresponding geometries may beany number of geometries including, but not limited to, an oval shape 74(FIG. 7) or a rectangular shape 76 (FIG. 8) or a tapered shape 84 (FIG.8A). The glass guide 40 is typically a plastic material, but it isconceivable that several other materials may be suitable. Rather thanconstructing the entire glass guide 40 of a single material, such asplastic, the glass guide 40 may optionally include a rigid insert 43,such as metal, to provide additional structural integrity. Extendingaway from the engagement section 42 of the glass guide 40 is the bodyportion 44. The body portion 44 extends in a plane substantiallyparallel to the inboard surface 48 of the first glass piece 12. The bodyportion 44 of the glass guide 40 includes an inboard surface 78 andoutboard surface 80. At least part of the outboard surface 80 includes abonding adhesive as well as an adhesion primer to ensure proper adhesionthat securely engages the body portion 44 of the glass guide 42 to theinboard surface 48 of the first glass piece 12. This secure engagementallows the glass guide 40 to travel in a substantially verticaldirection with the first glass piece 12 as the first glass piece 12moves up or down in a substantially vertical direction. During suchmovement, the engagement section 42 of the glass guide 40 travelssmoothly within the seal 36 and does not chuck or bind as a result ofsuitable controlled tolerances, and the presence of the low frictioncoating or other known material 38 within the inner surface 72 of theseal 36. One or more sealing lips 45 (FIGS. 5, 6, 10 and 11) may beemployed to ensure continuous sealing between the inboard surface 48 ofthe glass piece 12 and the glass guide 40, as well as optionally theretaining structure 32.

Additionally, to minimize or eliminate the appearance of the glass guide40 and any associated adhesive, when looking at the vehicle from theexterior, a frit material is included along the inboard surface 48 ofthe first glass piece 12 where the body portion 44 of the glass guide 40is present. The retaining structure 32 may optionally include arigidifying insert 52 to increase the structural integrity of theretaining structure 32. This rigidifying structure 52 may be of variousshapes, such as an I-beam shape, as illustrated in one embodiment, andmay be of various materials, including metal according to otherembodiments.

The previously described retaining structure 32 was discussed in thecontext of associating with the rear edge 54 of the first glass piece12. A similar retaining structure 32, as shown in FIGS. 9-11, may bepresent proximate any edge of either the first or second glass piece 12,14. Specifically, such a retaining structure 32 may be present at thefront edge 56 of the second glass piece 14, the rear edge 54 of thesecond glass piece 14, and/or the front edge 56 of the first glass piece12, in addition to the previously described position of the rear edge 54of the first glass piece 12. The key distinction between the variouspositioning of the retaining structure 32 pertains to orientation of theglass guide 40. When positioned at a rear edge 54, the glass guide 40will extend away from the seal 36 towards the front of the vehicle,whereas when positioned at a front edge 56 of the first or second glasspiece 12, 14, the glass guide 40 will extend away from the seal 36towards the rear of the vehicle.

In addition to one or more appliqués disposed between the first andsecond glass pieces 12, 14, the glass guiding and stabilization system10 may be configured such that no structural object is disposed betweenthe first and second glass pieces 12, 14, according to a secondembodiment. Specifically, the rear edge 54 of the first glass piece 12comes into contact with the front edge 56 of the second glass piece 14as shown in FIGS. 12-14. In this embodiment, a first guide 100 is bondedto the inboard surface 48 of the first glass piece 12 proximate the rearedge 56 of the first glass piece 12. A second guide 102 is bonded to theinboard surface 48 of the second glass piece 14 proximate the front edge56 of the second glass piece 14. The bonding substance is similar tothat described in the previous embodiment. The guides 100, 102 slidewithin coated seals having a corresponding geometry to the seals 36,102, as described in the previous embodiment.

Referring to FIG. 15, in this embodiment each glass piece 12, 14 travelsup and down in a substantially vertical direction between a raised and alowered position, but this movement is not truly vertical. Instead, thefirst glass piece 12 moves slightly rearward, with respect to thevehicle, as the first glass piece 12 is moved from a lowered position tothe raised position. Similarly, the second glass piece 14 moves slightlyforward, with respect to the vehicle, as the second glass piece 14 ismoved from a lowered position to the raised position. It is only whenboth glass pieces 12, 14 are in the fully raised position that the rearedge 56 of the first glass piece 12 is in contact with the front edge 54of the second glass piece 14. It is also conceivable that only one ofthe glass pieces 12, 14 is moveable between a lowered and raisedposition, according to a further embodiment. The first and second glasspieces 12, 14 are bonded to guides 100, 102, respectively, in a similarfashion as that described above, with respect to the bonding of theglass pieces 12, 14 to glass guide 40. The guides 100, 102 slidablyreside, at least in part, within channels 122 that are secured to theautomobile body side metal 120. The securing of the channels 122 to themetal 120 may be achieved by welding, bolting, riveting, etc. These aremerely a few illustrative examples. Additionally, the channels 122 maybe secured to the aforementioned daylight opening module 16.

A third embodiment of the flush glass assembly 11 having the glassguiding and stabilization system 10 is shown in FIGS. 16-18 which doesnot include an appliqué 32 between the first and second glass pieces 12,14, and instead merely has a flexible seal arrangement 200 disposedbetween the first and second glass pieces 12, 14. Additionally, andsimilar to previous embodiments, the first and second glass pieces 12,14 are bonded to guides 202 that slidably reside, at least in part,within channels 222 that are secured to the automobile body side metal220 or a form of the daylight opening module 16 in a manner previouslydescribed. The seal arrangement 200 comprises a seal component 208 thatextends from the guide 202 discussed above. The seal 208 is typically anextension of the guide 202 and closes out a small gap 204 between thefirst and second glass pieces 12, 14, while also sealing the gap 204 toprevent debris and air from entering the interior of the vehicle. In anycase, the seal 208 will have an outboard surface 206 that issubstantially parallel to the single plane formed by the outboardsurfaces 50 of the first and second glass pieces 12, 14. The seal 208(FIG. 18) may optionally include a structural rigidifying insert 210,depending on the particular application.

Referring to FIG. 18A, a seal 208 is shown representing an embodimenthaving a buffer, such as an appliqué, between the first and second glasspieces 12, 14 above the belt line, described in detail previously. Basedon the detailed disclosure provided above, structural components havebeen omitted to more clearly represent an alternate sealing arrangementthat includes the seals 208 positioned at extreme edges of the first andsecond glass pieces 12, 14. The illustrated embodiment shows two seals208 employed to close out the gap 204, but a single seal 208 may bemounted to the appliqué. Such an appliqué may include a flange thatextends perpendicularly to the appliqué surface, in an inboarddirection, having one or more locking features. The locking featuresfunction to engage gripping features present on the seal 208.

The first and second doors 22, 24 each comprise a lower door frame 300as seen in FIGS. 19-23 that includes an outer panel 302 and an innerpanel 304, with both the outer panel 302 and the inner panel 304 havinga front edge 306 and a rear edge 308. The lower door frame 300 will bedescribed generally, but it is noted that the lower door frame 300 maytake on any number of configurations to accommodate various automobilemodels, including sedans, coupes, convertibles, trucks, SUVs,crossovers, etc. The specific model will dictate, in part, the detailsof the lower door structure 300 components, with respect to geometry,arrangement, location, etc.

A gap 310 is provided between the outer panel 302 and the inner panel304 that is large enough to house the first or second glass piece 12,14, respectively. As discussed above, the glass guide 40 is operablyconnected to the inboard surface 48 of the first or second glass piece12, 14, with bonding being one example of such an operable connection.Also disposed between the outer panel 302 and the inner panel 304 is atleast one retaining bracket 312 that comprises a channel 314 which isconfigured similar to the retaining structure 32 described above. Theretaining bracket 312 and associated components may simply be anextension of the retaining structure 32 that was previously described ina configuration above the belt line of the door 22, 24. Such aconfiguration would allow the retaining bracket 312 to be assembled aspart of the daylight opening module 16. It is also conceivable that theretaining bracket 312 and/or the retaining structure 32 may be comprisedof multiple pieces that are placed in spaced alignment or in a directabutting alignment. The retaining bracket 312 may be secured to thelower door frame 300 at various locations, including the outer panel302, the inner panel 304, the front edge 306, and/or the rear edge 308.The retaining bracket may be secured to the lower door frame 300 bywelding, riveting, bolting, or by employing other mechanical fasteners.Additionally, as described above, the retaining bracket 312 may beformed as part of the daylight opening module 16 that includesextensions 330 (FIG. 4B) that descend downwardly into the lower doorframe 300. The extent of the descension will depending on numerousfactors, including the type of door, type of glass, whether the glass ismoveable or fixed, etc.

As is the case with the retaining structure 32, the channel 314 issealed and is configured to slideably retain the glass guide 40. In thecase of the first door 22, and more specifically the lower door frame300 of the first door 22, the retaining bracket 312 is located proximatethe rear edge 54 or the front edge 56 of the glass piece 12. There mayalso be a plurality of retaining brackets 312, for example, having oneretaining bracket 312 at each of the rear edge 308 and the front edge306. Additionally, as mentioned above, the retaining brackets 312 may bepositioned at various locations within the lower door frame 300, such asthe front and rear edges 306, 308 of the lower door frame 300 (FIG. 22)or alternatively the inner panel (FIG. 22A) of the lower door frame 300.The latter configuration may be particularly advantageous in anapplication that requires the glass pieces 12, 14, and/or 58 to beparticularly close in proximity to one another, such as where thevehicle lacks an appliqué or other large buffer between glass pieces.

The positioning of the retaining brackets 312 is dependent upon thedesired position of the glass pieces 12, 14. The glass guide 40 may bebonded to the glass pieces 12, 14 at any position to provideadjustability to the glass pieces 12, 14 positioning.

Referring to FIG. 25, a method for assembling the overall glass guidingand stabilization assembly 11, as well as the first door 22, is furtherillustrated. As described above, the upper door frame comprises adaylight opening module 16 that may be comprised of one or morecomponents. These components may include exterior trim componentsincluding, but not limited to, belts, belt seals, exterior trim,appliqués, badging a header molding, mirror mounts, and a mirror.Additionally, the daylight opening module 16 may include interior trimcomponents including, but not limited to, garnish molding, an innerbelt, and a mirror sail cover. It is conceivable that some or all ofthese components may be preassembled prior to installation of the door22 and/or 24 on the automobile. Irrespective of which components make upthe daylight opening module 16, by preassembling some or all of thecomponents, installation of the daylight opening module 16 isfacilitated in an efficient manner with superior fit and finishimprovements.

The daylight opening module 16 may simply be mounted over the firstglass piece 12, the second glass piece 14, and/or the quarter glasspiece 58. At least one portion of the daylight opening module 16 extendsbelow the belt shelf and is mechanically fastened to the lower doorframe 300 inner panel 304 and/or an extension of the outer panel 302.The daylight opening module 16 may be configured to include a side viewmirror assembly as shown in FIG. 24, according to one embodiment. In theevent the daylight opening module 16 does includes a mirror assembly 400(FIG. 24), the mirror assembly 400 may simply be installed prior to orduring daylight opening module 16 installation. It is also conceivablethat the mirror assembly 400 is not a component of the daylight openingmodule 16 and the mirror assembly 400 has been attached to the doormetal prior to installation of the daylight opening module 16. Thisattachment may be made by bolts, screws, clips, or any other suitablemechanical fastener 404. In this case, the daylight opening module 16includes an aperture 402 larger in area than that of the mirror 400 andis simply fit over the previously installed mirror assembly 400. Themirror assembly 400 may include several components, including a mirrorhead 406 and a mirror sail mount 408. Both the mirror head 406 andmirror sail mount 408 may be customized to various geometries to meetaerodynamic requirements and provide aesthetic design flexibility. Themirror assembly 400 is serviceable, while being integrated with theautomobile body or the daylight opening module 16.

It is important to note the manufacturing and assembly flexibilityprovided by the glass guiding and stabilization system 10. As previouslydescribed, the system 10 components may be assembled individually orcome in as an integrated daylight opening module 16. Flexibility isprovided by allowing the glass to be installed prior to module 16installation or subsequent to module 16 installation. In the case of theglass being installed prior to module 16 installation, the module 16 maysimply slide onto the glass guides 40 prior to moving the module 16downward to attach the module to the lower door frame 300. Conversely,installing the glass after installation of the module 16 allows theglass to simply “drop-in” to the flush glass assembly 11. The glassguides 40 may already be bonded to the glass and lowered into thechannel 34 of the retaining structure 32, and more specifically withinthe seal 36. Alternatively, it is conceivable that the glass guide 40 isbonded to the glass during or after dropping in the glass.

The flush glass assembly 11 advantageously provides for a “flush” glasswindow arrangement for a vehicle, thereby decreasing wind noise heard bya vehicle occupant, while adequately sealing proximate glass windowedges to prevent debris from entering the passenger area. Additionally,the glass guiding and stabilization system improves vehicle assemblymethods by providing enhanced flexibility, while also alleviatingassembly issues commonly associated with installation of doors, glasswindows, and other associated components. Based on the aforementionedflexibility, all or a portion of the described invention may be employedin various other automobile applications, such as a moonroof assembly.

It is to be understood that variations and modifications can be made onthe aforementioned structure without departing from the concepts of thepresent invention, and further it is to be understood that such conceptsare intended to be covered by the following claims unless these claimsby their language expressly state otherwise.

What is claimed is:
 1. A method for assembling an automobile doorcomprising: providing a lower frame comprising a movable glass piecedisposed within inner and outer panels; a daylight opening modulecomprising a glass guide; a retaining structure having a channel toslideably retain the glass guide; and an opening; assembling a side rearview mirror to the inner panel; sliding the module downward until aportion of the module contacts the inner panel; and securing the moduleto the inner panel, wherein the side rear view mirror is positionedsubstantially orthogonal to a plane of the glass piece, wherein the siderear view mirror is directly connected to the inner panel before thestep of sliding the daylight opening module downward, and wherein thestep of sliding the daylight opening module downward further comprisespositioning the opening over the side rear view mirror to receive therear view mirror within the opening.
 2. The method for assembling anautomobile door of claim 1 further comprising the step of bonding theglass guide to an inner surface of the movable glass piece.
 3. Themethod for assembling an automobile door of claim 2, wherein the step ofproviding the daylight opening module further comprises providing afixed glass piece assembled to the upper door frame.
 4. The method forassembling an automobile door of claim 2, wherein the step of providingthe upper door frame further comprises providing a trim garnishassembled to the daylight opening module.
 5. The method for assemblingan automobile door of claim 2, wherein the step of securing the daylightopening module to the inner panel comprises bolting the daylight openingmodule to the inner panel.
 6. The method for assembling an automobiledoor of claim 1, wherein the side rear view mirror is bolted to theinner panel after the step of securing the daylight opening module tothe lower door frame.
 7. A method for assembling an automobile doorcomprising: providing a lower frame comprising a movable glass piecedisposed within an inner panel and an outer panel; a daylight openingmodule comprising a glass guide; a retaining structure having a channelto slideably retain the glass guide; a first opening; and a secondopening; sliding the module downward until a portion of the modulecontacts the inner panel; securing the module to the inner panel; andbonding the glass guide to an inner surface of the movable glass piece,wherein a side rear view mirror is positioned substantially orthogonalto a plane of the glass piece, wherein the side rear view mirror isbolted to the inner panel before the step of sliding the daylightopening module downward, and wherein the step of sliding the daylightopening module downward further comprises positioning the second openingover the side rear view mirror to receive the rear view mirror withinthe second opening.
 8. A method for assembling an automobile doorcomprising: providing a lower door frame comprising an inner panel andan outer panel, wherein a movable glass piece is disposed substantiallywithin the inner panel and the outer panel; providing an upper doorframe comprising a daylight opening module, wherein the daylight openingmodule comprises a glass guide; a retaining structure having a channelto slideably retain the glass guide within the upper door frame and thelower door frame; and an opening; assembling a side rear view mirror toan attachment located at a position forward of the opening, wherein themirror extends substantially orthogonal to a plane of the movable glasspiece; sliding the upper door frame over a top edge of the glass pieceand downward until at least a portion of the upper door frame is incontact with the inner panel of the lower door frame; and securing theupper door frame to the inner panel, wherein the side rear view minor isdirectly connected to the inner panel before the step of sliding thedaylight opening module downward, and wherein the step of sliding thedaylight opening module downward further comprises positioning theopening over the side rear view mirror to receive the rear view mirrorwithin the opening.
 9. The method for assembling an automobile door ofclaim 8 further comprising the step of bonding the glass guide to aninner surface of the movable glass piece.
 10. The method for assemblingan automobile door of claim 9, wherein the step of securing the upperdoor frame to the inner panel comprises bolting the upper door frame tothe inner panel.
 11. The method for assembling an automobile door ofclaim 9, wherein the step of providing the upper door frame furthercomprises providing a fixed glass piece assembled to the upper doorframe.
 12. The method for assembling an automobile door of claim 9,wherein the step of providing the upper door frame further comprisesproviding a trim garnish assembled to the upper door frame.
 13. A methodfor assembling an automobile door comprising: providing a lower doorframe comprising inner and outer panels, a glass piece disposedsubstantially between the inner and outer panels and an opening;providing an upper door frame comprising a daylight opening modulecomprising a glass guide and an appliqué having a channel that includesa seal having a low friction coating to slideably retain the glassguide; assembling a side rear view mirror to the inner panel; slidingthe upper door frame over a top edge of the glass piece and downwarduntil at least a portion of the upper door frame is in contact with theinner panel; and securing the upper door frame to the inner panel,wherein the side rear view mirror is positioned substantially orthogonalto a plane of the glass piece, wherein the side rear view mirror isdirectly connected to the inner panel before the step of sliding thedaylight opening module downward, and wherein the step of sliding thedaylight opening module downward further comprises positioning theopening over the side rear view mirror to receive the rear view mirrorwithin the opening.
 14. The method for assembling an automobile door ofclaim 13 further comprising the step of bonding the glass guide to aninner surface of the glass piece, and wherein the daylight openingmodule is formed as a single molded piece.
 15. The method for assemblingan automobile door of claim 14, wherein the step of providing the upperdoor frame further comprises providing a mirror mounting componentassembled to the upper door frame.
 16. The method for assembling anautomobile door of claim 14, wherein the step of providing the upperdoor frame further comprises providing a trim garnish assembled to theupper door frame.
 17. The method for assembling an automobile door ofclaim 14, wherein the step of providing the upper door frame furthercomprises providing at least one belt seal assembled to the upper doorframe.
 18. The method for assembling an automobile door of claim 14,wherein the step of providing the upper door frame further comprisesproviding at least one glass run assembled to the upper door frame. 19.The method for assembling an automobile door of claim 13, wherein thestep of providing the daylight opening module includes joining multiplecomponents to form the daylight opening module.